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Chez,
"then, the in-tank fuel pump 10s test. i just left the main fuel pump unplugged, disconnected the return line" WRONG
The test is made at the Filter output, not the return line (see step #7 in previous post). For the little tank pump, the full system resistance (at the Return line) is too much.
Maybe, since the original problem—slow starts—seemed to go away when you buzzed the pumps before cranking, the easiest thing for now would be to just keep doing the fuse jumper bit. Or maybe rig it up to a switch on the dash. My cars used to have a lot of such "custom" wiring.
Since Fuse 7 is the input to the FI relay (and thus, the Main pump fuse) I'd wire from the Fuse 7 output (red wire) to Fuse 5 input (Y/Red wire), with a switch in between.
Or just connect the wire to fuse 5 input, and manually touch the free end to fuse 7 for "priming".
Bruce
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Bruce Young, '93 940-NA (current) '80 GLE V8 (Sold 5/03) '83 Turbo 245 '76 244 (lasted only 255,000 miles) 73 142 (98K) '71 144 (track modified--crusher bound) New 144 from '67 to '78 Used '62 122 from '63 to '67
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